Electrical Conduit Assembly
An OEM Manufacturer of molded plastic electrical conduit components was previously installing brass inserts of their own design, into several of their various products. Equipment used: A single horn ultrasonic welder. The operator would load the part into a nest, place an insert into the hole, and activate the unit. The insert was installed with great difficulty, due to undersized holes and an unconventional insert shape. The results were poor, and excess molten material created an un-sightly appearance, and often the insert was out of location. Secondary operations were required to remove the excess, and a high percentage of parts were rejected. They were making production at a rate of 1 finished part (2 inserts per part) per minute, sometimes longer depending on the complexity of the part.